Jegs 79009 User manual

Installation Instructions for 79009
Bottle Jack
20 Ton
Save the receipt, warranty and these instructions. It is important that you read the entire manual to become familiar with
this product before you begin using it.
This machine is designed for certain applications only. The distributor cannot be responsible for issues arising from
modification. We strongly recommend this machine not be modified and/or used for any application other than that for
which it was designed. If you have any questions relative to a particular application, DO NOT use the machine until you
have first contacted the distributor to determine if it can or should be performed on the product. For technical questions
please call 1-800-345-4545.
INTENDED USE
This Air/Hydraulic Bottle Jack is designed for lifting. The jack can be used vertically or angled to 3 degrees form vertical
position. After lifting, loads must be immediately supported by appropriate means. Each model is suitable for use in
lifting or positioning vehicles, machinery, houses and/or other building structures. These jacks comply with ASME PALD
Standards. For air actuated use, ensure that your air source has a working range of 100-120 PSI.
TECHNICAL SPECIFICATIONS
Description
Item
79009
Maximum Capacity
40,000 lbs.
Minimum Lift Height
10-7/16 in.
Maximum Lift Height
20-1/16 in.
Screw To Adjustment
3-1/8 in.
Rated Air Pressure PSI
Min. 100 - Max. 120 PSI
Product Size
6-3/8 in. x 9-7/16 in. x 20-1/8 in.
Weight
39 lbs.
Safe Operating Temperature is between 40°F - 105°F (4°C - 41°C)
GENERAL SAFETY RULES
WARNING: Read and understand all instructions. Failure to follow all instructions listed below may result in serious
injury.
CAUTION: Do not allow persons to operate or assemble this Jack until they have read this manual and have
developed a thorough understanding of how the Jack works.
WARNING: The warnings, cautions, and instructions discussed in this instruction manual cannot cover all
possible conditions or situations that could occur. It must be understood by the operator that common sense and
caution are factors that cannot be built into this product, but must be supplied by the operator.
SAVE THESE INSTRUCTIONS
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IMPORTANT SAFETY CONSIDERATIONS
JACK USE AND CARE
Do not modify the Jack in any way. Unauthorized modification may impair the function and/or safety and
could affect the life of the equipment. There are specific applications for which the Jack was designed.
Always check for damaged or worn out parts before using the Jack. Broken parts will affect the Jack
operation. Replace or repair damaged or worn parts immediately.
Store idle Jack. When Jack is not in use, store it in a secure place out of the reach of children. Inspect it for
good working condition prior to storage and before re-use.
Not for use by children or people with reduced mental capacity.
Do not use under the influence of drugs or alcohol.
Ensure children and other bystanders are kept at a safe distance when using crane.
INSPECTION
Inspect the jack carefully before each use. Ensure the jack is not damaged, excessively worn, or missing parts.
Do not use the jack unless it is properly lubricated.
Using a jack that is not in good clean working condition or properly lubricated may cause serious injury.
Inspect the work area before each use. Make sure it is free and clear of any potential hazards.
DO NOT OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL.
To maintain the Jack and user safety, the owner is responsible for reading and following these instructions.
Inspect the service jack for proper operation and function.
Keep instructions readily available for equipment operators. Make certain all equipment operators are properly
trained; understand how to safely and correctly operate the unit.
Allow unit operation only with all parts in place and operating properly.
Use only genuine replacement parts. Service and maintain the unit only with authorized or approved
replacement parts, negligence will make the jack unsafe for use and void the warranty.
Carefully inspect the unit on a regular basis and perform all maintenance as required.
Store these instructions in a safe place. Keep all decals on the unit clean and visible.
Safety: always follow safety precautions when installing and operating this jack.
Before proceeding ensure that you fully understand and comprehend the full contents of this manual.
Failure to operate this equipment as directed may cause injury or death.
The distributor is not responsible for any damages or injury caused by improper use or neglect
Always use Jack Stands!
DO NOT USE wood blocks or any other non-approved load sustaining devices. The manufacturer only warrants loads
to be sustained by jack stands that meet current ASME standards.
DO NOT USE wood blocks or any other non-approved lifting devices for a means of lifting with the jack and or load
being raised. Failure to head these warnings may cause injury or death.
WARNING:
1. Study, understand, and follow all instructions before operating this device.
2. Do not exceed rated capacity.
3. Use only on hard, level surfaces.
4. Lifting device only. Immediately after lifting, support the vehicle with appropriate means.
5. Do not move or dolly the vehicle while on the jack.
6. Lift only on areas of the vehicle as specified by the vehicle manufacturer.
7. No alterations shall be made to this product.
8. Only attachments and/or adapters supplied by the manufacturer shall be used.
9. Do not get under or allow anyone under the vehicle until it has been supported by jack stands.
10. Center load on saddle prior to lifting.
11. Use wheel chocks or other blocking device on opposing wheels before using jack.
12. Do not use this jack for any use other than the manufacturer specified usage.
13. Failure to heed these warnings may result in personal injury and/or property damage.
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GENERAL SAFETY INSTRUCTIONS
*Position the Jack
Position the jack to only lift on the areas of the vehicle as specified by the vehicle manufacturer.
*Always Use Jack Stands
After lifting the vehicle always support the load with appropriately rated vehicle Jack stands before working on the
vehicle.
*Do Not Overload Jack
Do not overload this jack beyond its rated capacity. Overloading this jack beyond its rated capacity can cause damage
to or failure of the jack.
*Always Use on Hard Level Surfaces
This jack is designed only for use on hard level surfaces capable of sustaining the load. Use on unstable surfaces may
result in possible loss of load.
* Chock and Block (Stabilize)
-Apply parking brake in vehicle before operating jack. -A chock is a wedge for steadying an object and holding it
motionless, or for preventing the movement of a wheel
-Chock the wheel opposite the end being lifted.
-When you block a load, you secure and support a load that is being lifted. The block(s) or stabilizer(s) should have a
weight capacity that is greater than the weight of the load which is being lifted.
*Center Load on Jack Saddle
Center the load on jack saddle before lifting vehicle.
Off-center loads and loads lifted when the jack is not level can cause loss of load or damage to the jack.
*Do not raise or lower the vehicle unless tools, materials and people are clear.
When the lift is being lowered, make sure everyone is standing at least six feet away. Be sure there are no tools or
equipment left under or around the jack before lowering.
*Always lower the jack slowly.
DO NOT USE THE JACK TO SUPPORT OR STABILIZE A LOAD.
Using the jack to support or stabilize a load may result in unexpected movement and result in serious injury, being
crushed and death. Always securely chock and block (stabilize) the load to be lifted. Never place any part of the body
under a raised load without properly chocking and supporting the load.
*Never use the jack on curved or tubular vehicle
Bumpers, this will result in the vehicle slipping off the jack and falling, causing serious injury or death. Use a bumper lift
for vehicles with curved bumpers or plastic bumpers.
*Wear ANSI-approved safety glasses and heavy-duty work gloves during use.
*Do not adjust the safety valve.
*Do not move or dolly vehicle while jack is in use.
*Stay alert. Use caution and common sense when operating jack. Do not use a jack if you are tired, incoherent,
dizzy, or under the use or drugs or alcohol.
Training
-Read this manual before use. Do not allow anyone who has not read this manual, and/or does not understand the
requirements, to use the jack.
Spectators
-Do not allow bystanders around the jack or under the load supported only by the jack. -Do not allow anyone in the
vehicle while the jack is in use. Keep all bystanders away from vehicle when in use.
Inspection
-Inspect the jack carefully before each use. Ensure the jack is not damaged, excessively worn, or missing parts. -Do not
use the jack unless it is properly lubricated. -Using a jack that is not in good clean working condition or properly
lubricated may cause serious injury.
Additional Notes:
Save the receipt, warranty and these instructions.
Do not modify the jack in any way. Unauthorized modification may impair the function and/or safety and could affect
the life of the equipment. There are specific applications for which the jack was designed.
Always check for damaged or worn out parts before using the jack. Broken parts will affect the equipment operation.
Replace or repair damaged or worn parts immediately.
When jack is not in use, store it in a secure place out of the reach of children. Inspect it for good working condition prior
to storage and before re-use.
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ASSEMBLY
1. Familiarize yourself with the jack.
Saddle
Lift Control Valve
Carry Handle
2pc Handle Air Motor
Release Valve
2. Attach the 2 handle pieces making sure to align the holes on both sections.
3. Line up the handle to the handle socket located on the side of the jack, then insert the handle inside the handle
socket.
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4. Secure the handle in place inside the handle socket. Without any vehicle on the jack. Cycle the lift up and down
several times to insure the hydraulic system is operating properly. (Perform to the Air Purge Procedure before first use.)
SYSTEM AIR PURGE PROCEDURE
IMPORTANT: BEFORE FIRST USE
Perform the following Air Purge Procedure to remove any air that may have been introduced into the hydraulic system
as a result of product shipment and handling. This step is to be completed without any weight on the jack.
1. Turn release valve counterclockwise on full turn to the open position.
2. Rapidly pump the handle 6-8 times. Leave handle in down position to expose oil fill plug.
3. With a flat blade screwdriver, push the oil fill plug slightly to the side to purge trapped air from system. (Use caution
not to tear or puncture the oil plug.)
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4. Turn release valve clockwise to the closed position.
5. Jack is now ready for use. Check for proper pump action.
BEFORE USE
1. Before using this product, read the owner's manual completely and familiarize yourself thoroughly with the product
and the hazards associated with its improper use.
2. Perform the air purge procedure. (See previous instructions for system purge procedure.)
3. Pour a teaspoon of good quality, air tool lubricant into the air supply inlet of the lift control valve. (See illustration)
Connect to air supply and operate for 3 seconds to evenly distribute lubricant.
4. Check and that the pump operates smoothly before putting into service.
5. This product uses a standard 1/4" NPT air fitting. If changing of the fitting is required, install a 1/4" NPT fitting of your
choice; ensure that thread tape or compound is used to seal connection.
6. Inspect before each use. Do not use if bent, broken or cracked components are noted.
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OPERATION
RAISING THE JACK
1. Block the vehicle's wheels for lifting stability. Secure the load to prevent inadvertent shifting and movement.
2. Position the jack near desired lift point.
3. Set the Parking Brake in the vehicle.
4. Refer to the vehicle manufacturer owner's manual to locate approved lifting points on the vehicle. Position the jack so
that the saddle is centered and will contact the load lifting point firmly.
5. Assemble the handle; ensure that spring clips align with slots.
6. Close the release valve by turning it clockwise until it is firmly closed.
7. Before raising the vehicle double check and verify the saddle is centered and also has full contact with the lifting
point.
8. Pump handle or squeeze air trigger to lift until saddle contacts load. (To stop air operation, simply release the grip on
the lift control valve.) Continue to pump the jack handle to lift the vehicle to the desired height. After lifting, support the
load with appropriately rated vehicle support stands before working on the vehicle.
CAUTION: NEVER WIRE, CLAMP OR OTHERWISE DISABLE THE LIFT CONTROL VALVE TO FUCTION BY
ANY MEANS OTHER THAN BY USING THE OPERATOR'S HAND. USE THE HANDLE PROVIDED WITH THIS
PRODUCT OR AN AUTHORIZED REPLACEMENT HANDLE TO ENSURE PROPER RELEASE VALVE OPERATION.
DO NOT USE EXTENSIONS ON THE AIR HOSE OR ON THE OPERATING HANDLE.
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LOWERING THE JACK
1. Raise load high enough to allow clearance for the jack stands to be removed, then carefully remove jack stands.
2. Remove support stands.
3. Grasp the handle firmly with both hands. Securely hold on to the jack handle so your hands do not slip and ensure
the release valve does not rapidly lower.
4. Carefully open the Release Valve by slowly turning the handle counterclockwise. (Do not allow bystanders around
the jack or under the load when lowering the jack.
5. After removing jack from under the load, push ram and handle sleeve down to reduce exposure to rust and
contamination.
WARNING: USE EXTREME CAUTION WHEN LOWERING THE JACK. THE JACK HANDLE MAY TURN RAPIDLY.
OPENING THE RELEASE VALVE TOO FAST CAN CAUSE THE JACK TO LOWER RAPIDLY. FAILURE TO HEAD
THESE WARNINGS COULD CAUSE SERIOUS INJURY OR DEATH.
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MAINTENANCE INSTRUCTION
If you use and maintain your equipment properly, it will give you many years of service. Follow the maintenance
instructions carefully to keep your equipment in good working condition. Never perform any maintenance on the
equipment while it is under a load.
Inspection
You should inspect the product for damage, wear, broken or missing parts (e.g.: pins) and that all components function
before each use. Follow lubrication and storage instructions for optimum product performance.
Binding
If the product binds while under a load, use equipment with equal or a larger load capacity to lower the load safely to
the ground. After un-binding; clean, lubricate and test that equipment is working properly. Rusty components, dirt, or
worn parts can be causes of binding Clean and lubricate the equipment as indicated in the lubrication section. Test the
equipment by lifting without a load. If the binding continues contact Customer Service.
Cleaning
If the moving parts of the equipment are obstructed, use cleaning solvent or another good degreaser to clean the
equipment. Remove any existing rust, with a penetrating lubricant.
Lubrication
This equipment will not operate safely without proper lubrication. Using the equipment without proper lubrication will
result in poor performance and damage to the equipment. Some parts in this equipment are not self-lubricating inspect
the equipment before use and lubricate when necessary. After cleaning, lubricate the equipment using light penetrating
oil, lubricating spray.
-Use a good lubricant on all moving parts.
-For light duty use lubrication once a month.
-For heavy and constant use lubrication recommended every week.
-NEVER USE SANDPAPER OR ABRASIVE MATERIAL ON THESE SURFACES!
Rust Prevention
-Check rams and pump plungers on the power unit assemblies daily for any signs of rust or corrosion.
Without a load lift the equipment as high as it goes and look under and behind the lifting points. If signs of rust are
visible clean as needed.
Grease Fittings
-Some models contain grease fittings that will regularly need to be greased and lubricated.
How the Jack Operates
With release valve closed, an upward stroke of the jack handle draws oil from the reservoir tank into the plunger cavity.
Hydraulic pressure holds the valve closed, which keeps the oil in the plunger cavity. A downward stroke of the jack
handle releases oil into the cylinder, which forces the ram out. This raises the saddle. When the ram reaches maximum
extension, oil is bypassed back into the reservoir to prevent an over extended ram stroke and possible damage to the
jack. Opening the release valve allows oil to flow back into reservoir. This releases hydraulic pressure on the ram,
which results in lowering the saddle.
Storing the Jack
1. Lower the Lifting Arm.
2. Place the handle in the upright position.
3. Store in a dry location, recommended indoors.
Note: If the jack is stored outdoors, be sure to lubricate all parts before and after use to ensure the jack stays in good
working condition.
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TO ADD JACK OIL:
1. Position the jack on level ground and lower the saddle.
on level ground
2. Remove the oil plug.
Oil Plug
3. Fill the oil case until oil level is just beneath the lower rim of the oil fill hole.
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4. Replace oil plug.
5. Perform the Air Purge Procedure.
TO REPLACE JACK OIL:
1. Position the jack on level ground and lower the saddle.
on level ground
2. Open release valve by turning handle counter-clockwise (4 full turns).
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3. Remove the oil fill plug.
4. Turn the jack on its side so that old oil will drain from the oil fill hole.
5. Position the jack on level ground and lower the saddle.
on level ground
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6. Fill the oil case until oil level is just beneath the lower rim.
KEEP DIRT AND OTHER MATERIAL CLEAR WHEN POURING.
7. Replace oil plug.
8. Perform the Air Purge Procedure.
ADDITIONAL WARNINGS:
DO NOT USE MOTOR OIL IN THE JACK.
ONLY USE ANTI-FOAMING JACK OIL.
ALWAYS USE A GOOD GRADE HYDRAULIC JACK OIL.
DO NOT USE HYDRAULIC BRAKE FLUID, ALCOHOL, GLYCERINE, DETERGENT, MOTOR OIL OR DIRTY
OIL.
USE OF A NON-RECOMMENDED FLUID CAN CAUSE DAMAGE TO A JACK.
AVOID MIXING DIFFERENT TYPES OF FLUID AND NEVER USE BRAKE FLUID, TURBINE OIL,
TRANSMISSION FLUID, MOTOR OIL OR GLYCERIN. IMPROPER FLUID CAN CAUSE PREMATURE FAILURE
OF THE JACK AND THE POTENTIAL FOR SUDDEN AND IMMEDIATE LOSS OF LOAD.
DISPOSE OF HYDRAULIC FLUID IN ACCORDANCE WITH LOCAL REGULATIONS.
Additional Bottle Jack Notes:
Periodically check the pump piston and ram for signs of rust or corrosion. Clean as needed and wipe with an oil
cloth. NEVER USE SANDPAPER OR ABRASIVE MATERIAL ON THESE SURFACES!
When not in use store the jack with pump piston and ram fully retracted.
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ASSEMBLY DIAGRAM
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PARTS LIST
Index #
Description
Qty.
1
Spring Plate
1
2
Spring
2
3
Reservoir
1
4
Filler Plug
1
5
Cup Seal
1
6
Top Nut
1
7
O-Ring 42.5 x 3.55
1
8
Ram
1
9
Piston
1
10
Cup Seal
1
11
Y-Ring
1
12
Cylinder
1
13
Seal Ring
1
14
Seal Ring
1
15
Threaded sleeve
1
16
Extension Screw
1
17
Pneumatic switch
1
18
Air Hose
1
19
Connector
1
20
Air Motor
1
21
Handle Sleeve
1
22
Dust Ring
1
23
Pump Plunger
1
24
Seal Ring
2
25
O-Ring 6.5 x 3
2
26
Grease filter
1
27
Ball stopper
2
28
Spring screw M8
1
29
Pin D4 x 22
1
30
Washer
2
31
Handle
1
32
Handle
1
33
Release Valve
1
34
O-Ring 7.7 x 1.9
1
35
Base
1
36
Nut M8
2
37
Conical Screw M8
2
38
Ball 3
1
39
Spring Seat
1
40
Spring
1
41
O-Ring 5.8 x 2.8
1
42
Regulating Screw
1
43
Cover
1
44
Screw M8 x 8
2
45
Ball 6
8
46
Ball 9
2
47
Spring
1
48
Screw M12 x 1.25 x 10
2
49
Pump Cylinder
1
50
Seal Ring
1
51
Platen
1
52
Axis
3
53
Pin
3
54
Link
1
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TROUBLESHOOTING
JACK
WILL
NOT
LIFT
LOAD
JACK
WILL
NOT
HOLD
LOAD
JACK
WILL
NOT
LOWER
POOR
JACK
LIFTING
WILL NOT
LIFT TO
FULL
EXTENSION
CAUSES AND SOLUTIONS
X
X
X
Release valve is not completely closed (Turn
handle clockwise).
X
Air Supply Inadequate
X
Weight Capacity Exceeded.
X
X
Air is in the hydraulics.
Purge air from system.
X
X
X
X
Low oil level. Add oil as required.
X
Oil reservoir is overfilled:
Drain excessive oil.
Lubricate moving parts.
X
Jack is binding or foreign obstruction
X
X
X
Power unit malfunctioning.
Replace the power unit.
Safe Operating Temperature is between 400°F - 105°F (40°C - 41°C).
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